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Home spun XHP70 driving lights

Discussion in 'The Garage' started by mrsdnf, Oct 5, 2019.

  1. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    Riding at night its obvious we need good lights especially here in Oz where the night life is doing its best to destroy you when you least expect it.
    It amuses me how many bike tests these days do not mention how good or bad the headlights are.
    Needless to say the headlight on my SWM SD is pretty underwhelming.
    With a brand name H4 globe swap low beam in conjunction with the standard day time LED running lights (or whatever they call them) is passable. Hi beam though is still really lacking.
    Jaycar, Oz electronics store, had a run out on some old style MTG2 LED driving lights which I purchased and installed on the SD running there own power supply and relay. Hi and low beam were also hooked up to this power supply directly from the battery and also run their own relays. Hi beam was now not to bad.
    The Jaycar MTG2 LED lights installed on the SD.

    [​IMG]

    Having custom built quite a few LED torches over the years I knew the Jacar driving lights could be improved on so the decision was made to make a couple of compact driving lights from scratch.
    I want to keep the size of the lights similar to the Jaycar lights due to room constraints.

    A list of parts was made and the purchasing begun resulting in this stash of parts landing on my work bench.
    The reflectors are Illuminations Machines XML 4. This reflector was tested with the XHP70.2 led to make sure it was suitable which it was. The opening is 70mm in diameter. This is a four degree reflector and is also made as a ten degree reflector. An option if I want more flood than throw.
    A couple of polycarbonate lenses custom made for me by a mate lostheplot who has just finished a light bar running 12 C8 reflectors with XHP50 LEDS.
    The drivers are from Russia compliments of Fleabay and should drive the 6 volt XHP70.2 at a moderate 4 amps each.
    The XHP70.2 LEDS are 5000K and mounted to direct thermal path copper 20mm MCPCB's. The XHP70.2 LED are made up of four XML sized, 5mm, LEDS.
    The relays are tiny PCB mount, from memory each can handle about 30amps.
    And finally a sketch of the internal dimension of the reflector end of the housing.
    [​IMG]
    #1
    Mr Head, AUSSIEADV, Rotax655 and 3 others like this.
  2. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    90mm aluminium bar was purchased and two pieces cut off at 65mm in length. This was faced one end.

    [​IMG]

    And the internals machined for the reflector and lens.

    [​IMG]

    The OD was turned down and threaded for the Bezel. The groove is for an o'ring to keep the elements out.

    [​IMG]

    Something was needed to hold the housing so it could be held to machine the rest of it. The scrap bin was emptied out and this piece of material was given a second life. Its one of three similar rejects and has had about eight hours of machine work along with a considerable amount of money spent buying the material to end up in the scrap bin.

    [​IMG]
    #2
  3. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    The material above is the slotted piece in this picture with the two grooves above the slots and copper tubes for the air to exhaust from. Inside is a cooling fan.

    [​IMG]

    Anyway this scrap piece was not making life easy as the diameter was machined to large for the thread. Yes it was my fault.

    [​IMG]

    At last with no mistakes the mandrel was finished after turning it around and machining the opposite side.

    [​IMG]

    And the two parts united as one.

    [​IMG]
    #3
  4. Suncoaster

    Suncoaster Long timer Supporter

    Joined:
    Jul 7, 2015
    Oddometer:
    1,392
    Location:
    Where the girls are green and the grass is pretty.
    Beamshots !
    #4
    mrsdnf likes this.
  5. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    Patience Suncoaster. You know me better than anyone else and how slack I am. I haven't built any more than whats above. Still waiting on o'rings to turn up. :D
    #5
    silverbandit1 and Suncoaster like this.
  6. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    Work started on the bezels next. These hold the lens and reflector in place. A piece of 90mm bar was machined to the ID and parted of to the length of two bezels plus the width of the parting off tool.

    [​IMG]

    The inside was stepped and threaded to suit the head and lens. An o'ring groove was machined into the step to seal the lens from water entering

    [​IMG]

    This was the parted off and the head placed in the chuck with the bezel threaded to it for the outside profile to be machined.

    [​IMG]

    And then there were two.

    [​IMG]
    #6
    Mr Head, silverbandit1 and Suncoaster like this.
  7. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    The holes were then drilled in the head for the led DTP MCPCB to be screwed down and the wiring to enter from the driver pocket. The holes here are all 2.5mm out and were re machined later when I discovered my mistake. Whoops.

    [​IMG]

    The driver will sit in its own bolt on housing as all the wiring is on one side of the circuit board.
    The OD of this is 50mm x 25mm in width.

    [​IMG]

    The two 5mm holes for retaining this housing to the head and another hole was drilled and tapped for the cable gland. The small centre mark is so I can locate the centre of the pocket yet to be machined for the driver to sit in.

    [​IMG]

    The housing was then flipped over so the holes could be stepped down.

    [​IMG]
    #7
    Mr Head and silverbandit1 like this.
  8. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    The four jaw chuck was then used to locate the driver housing for the driver pocket to be bored.

    [​IMG]

    Back to the mill and a 4mm end mill was set up to machine grooves for extra surface area and hopefully better cooling of the driver.

    [​IMG]

    [​IMG]

    And finally the heads were given a bit of profile on the outside, driver housing pocket machined and an o'ring groove machined to keep the elements out.

    [​IMG]
    #8
  9. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    The driver housings, one with the driver installed. The retaining screws are 2mm. I've broken more than my fair share of these taps. All went well here.

    [​IMG]

    The heads were set up to allow flats to be machined and the mount holes drilled.

    [​IMG]

    Nearly finished.

    [​IMG]

    And we are done for today. Just the cooling fins to go.
    The mounting threads are 6mm Helicoils. If these are not big enough I'll use 8mm at a later date.

    [​IMG]
    #9
  10. silverbandit1

    silverbandit1 Adventure Dreaming..

    Joined:
    Jun 5, 2004
    Oddometer:
    1,690
    Location:
    NorCal
    :lurk
    #10
  11. Mikie1

    Mikie1 Adventurer

    Joined:
    Jun 8, 2008
    Oddometer:
    16
    Just... Wow.
    Wish I had that kind of talent!
    #11
    sidetrack one and mrsdnf like this.
  12. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    Thanks Mikie1.
    Not sure about talent, more like to much time to waste.
    Got the fins on one body finished last night. Need more time to get the second completed.
    A mate is laser cutting me some Stainless brackets for a cheap price. The end is getting closer.
    #12
    Suncoaster likes this.
  13. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    Back to the Mill for the heads. The grooves are 6mm in width leaving the fins 4mm in width. These are machined on a nine degree angle, three degrees more than the taper on the outer diameter of the head.
    The first of many grooves and the start of a crook back (lots of time bent over).

    [​IMG]

    And finally finished. One of the grooviest jobs I've ever done.

    [​IMG]

    And with a bit of polishing we have some finished components.
    Firstly the driver housings.

    [​IMG]

    Bezels.

    [​IMG]
    #13
    Suncoaster likes this.
  14. mrsdnf

    mrsdnf Long timer

    Joined:
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    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    And the heads.

    [​IMG]

    [​IMG]

    [​IMG]

    Assembly can now be started and hopefully I'll have the mounting brackets next week.
    #14
  15. Suncoaster

    Suncoaster Long timer Supporter

    Joined:
    Jul 7, 2015
    Oddometer:
    1,392
    Location:
    Where the girls are green and the grass is pretty.
    Groovy, man!
    #15
    mrsdnf likes this.
  16. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    With the MOTOGP qualifying cancelled I had more time in the shed than planned.
    The driver pocket was machined to a depth of approx 1 thousandth of an inch extra depth for clearance on the chips on the back of the driver that need to be heatsinked. Heatsink compound was added to the chips and the drivers permanently installed.

    [​IMG]

    I've made enough magic smoke over the years to learn that at every step doing the electrics test what you have done. Power was hooked up and a deep breath taken as the switch was flicked to on.

    [​IMG]

    [​IMG]

    Whew. No magic smoke.

    With the lights assembled they were tested again.

    [​IMG]
    #16
    Mr Head likes this.
  17. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    [​IMG]

    From about 4 meters.

    My type of porn complete with dirty finger prints.

    [​IMG]

    [​IMG]
    #17
  18. 9w6vx

    9w6vx Pergo et Perago

    Joined:
    Aug 30, 2019
    Oddometer:
    137
    Location:
    BKI Sabah
    Wow..... top drawer stuff!
    #18
  19. Suncoaster

    Suncoaster Long timer Supporter

    Joined:
    Jul 7, 2015
    Oddometer:
    1,392
    Location:
    Where the girls are green and the grass is pretty.
    Magnificent job as usual !
    #19
  20. mrsdnf

    mrsdnf Long timer

    Joined:
    Feb 8, 2019
    Oddometer:
    1,102
    Location:
    Lost between the Dandenongs and Yarra Valley
    The finished lights mounted up and in their natural environment complete with bug spatter.

    [​IMG]

    [​IMG]

    [​IMG]
    #20